Merrow Border Vs Hot Cut Edge

Just like there are many options for patch backing where you can go for the one which you feel the most comfortable with, the  awesome world of custom patches also offers variety when it comes to borders. Granted there are only two popular choices but do you know that it is these two options which hold the weight of almost 90% of custom patches produced annually. Yes 90% – it is insane number. That is why today we have decided to learn about these two options (Merrow Border vs Hot Cut Edge) in detail so that you can make the correct decision.

About Merrow Border

Known as an overlocked border, Merrow Border is a type of stitched edge commonly used in the production of embroidered patches. For those who don’t know this technique or this border originated from the Merrow Machine Company, which itself was founded in the 19th century. So, you can imagine that it has been indeed hundred of years since these are used for patches. This company which specialized in creating sewing machines set the standard for creating durable and visually appealing patch borders using Merrow!

Fast forward to now and today Merrow machines are used all around the world. These machine uses a series of looped stitches to encase the raw edges of the patch fabric, preventing fraying and giving the patch a finished, professional look. However, what many does not know is that unlike the machines in the past that are used now (or that we use at ZmCustomPatches) have a special power, and that power is that they are so precise. Modern sewing machines have the ability to handle different thread types and colors which make it ideal for producing the distinctive Merrow border.

If we were to summarize the key features of Merrow Borders this is how it goes in three lines:

• Thick, Raised Edge: The Merrow border is characterized by its thick, raised edge that provides a sturdy and pronounced frame around the patch.
• Typically About 1/8 Inch Wide: The border width is usually around 1/8 inch, offering a balanced and consistent appearance suitable for various patch sizes.
• Available in Various Colors: Merrow borders can be created in a wide range of colors, allowing them to match or contrast with the patch design. This flexibility enhances the visual appeal and customization options for the patch.

Hot Cut Edge 101

Unlike the traditional approach Merrow approach the Hot Cut Edge is a more modern approach for crafting borders of a custom patch. The hot cut edge technique involves using heat to cut and simultaneously seal the edges of the fabric. This is achieved by applying a high-temperature cutting tool to the fabric, which melts the edges as it cuts through. The heat seals the fibers together, preventing them from unraveling.

If you are still finding yourself scratching your head because the above written passage didn’t make it clear, understand this thing first:

• Hot Knife: A hot knife is a handheld tool with a heated blade designed to cut through synthetic fabrics. The blade heats up to a temperature that can melt the fabric as it cuts, creating a sealed edge. This tool is ideal for small-scale operations and provides a high degree of control over the cutting process.

Since hot knife is basic or inherent to the model of Hot Cut Edge there is no need for further simplification although you should know that laser  cut is also used at places.

• Laser Cutter: A laser cutter uses a focused laser beam to cut through materials. It is controlled by a computer, allowing for precise and intricate designs to be cut with high accuracy. As the laser cuts through the fabric, the heat from the laser seals the edges. This tool is suitable for large-scale production and can handle complex shapes and detailed designs efficiently.

As for features just like Merrow border this one also tops the chart and rightfully so, just look at this list:

• Thin, Sealed Edges: The edges created by the hot cut method are thin and neatly sealed. This prevents fraying and ensures the patch maintains a clean appearance over time.
• Allows for Precise and Clean Cuts: The use of heat in cutting allows for very precise and clean edges. This is particularly important for patches with detailed and complex designs, where precision is crucial.
• Suitable for Intricate Shapes and Detailed Designs: The hot cut technique is well-suited for creating patches with intricate shapes and fine details. The precision of tools like laser cutters makes it possible to accurately reproduce complex designs without compromising the quality of the edges.

Key Differences

The key difference between Merrow and hot cut edges lies in their construction and appearance. A Merrow border, created using a Merrow machine, features a thick, raised, and overlocked edge that encases the patch’s perimeter with a series of looped stitches. This border is typically about 1/8 inch wide, offering enhanced durability and a polished, traditional look, suitable for simple shapes like circles and rectangles.

In contrast, a hot cut edge is achieved by using a hot knife or laser cutter to cut and simultaneously seal the edges of the fabric with heat. This method produces thin, sealed edges that prevent fraying and allow for precise, clean cuts, making it ideal for patches with intricate shapes and detailed designs. While Merrow borders provide a robust, classic finish, hot cut edges offer flexibility and a modern, sleek appearance, catering to different aesthetic preferences and practical needs in patch creation.

Choosing the Right Border

 

Choosing between a Merrow border and a hot cut edge depends on the specific needs of the patch design, intended use, and desired appearance.

• Merrow Border: Ideal for patches that require a durable, traditional look with simple shapes. Best for sewn applications needing extra edge reinforcement.
• Hot Cut Edge: Perfect for patches with intricate designs needing precise cuts and a sleek, modern look. Suitable for iron-on or adhesive-backed applications where flexibility and thin edges are advantageous.